Air handler and insert for the same

ABSTRACT

An air handler and an insert for the same are provided. The air handler has a housing, an air conditioning element, and a first air outlet in the housing. The air conditioning element is disposed in an air passage in the housing through which air is moved by a fan. At least one wall of the air passage within the housing tapers the air passage between the air conditioning element and the first air outlet.

TECHNICAL FIELD

The following relates generally to climate control. In particular, the following relates to an air handler and an insert for the same.

BACKGROUND

Air handlers are well known. An air handler draws air from an environment, conditions it by either cooling, warming, humidifying, or dehumidifying it via an air conditioning element, and forces it through a set of ducts that services areas of a space. Where heating is provided, typically hot water from a water heater is pumped through a heat exchanger coil located in the air handler. Air passed over the heat exchanger coil is heated by the temperature differential of the hot water and the air, and then impelled through the ductwork to heat the areas.

One such air handler 20 is shown in FIG. 1. The air handler 20 is a high-velocity air handler that has a housing 24 with a return port 28 at a lower end thereof. The return port 28 permits the ingress of return air from an environment being conditioned. The return port 28 can be coupled to ducting through which return air is drawn. A blower fan positioned in a lower portion 32 inside the housing 24 draws the return air and forces an air stream upwards through a heat exchanger coil. The heat exchanger coil has an inlet port 36 and an outlet port 38 that are coupled via conduits to a water heater, such as an instantaneous water heater. A pump circulates water from the water heater through the heat exchanger coil via the conduits. As the air stream passes through the heat exchanger coil, the air is heated before it is forced upwards through a plenum 40 of the air handler 20 downstream of the heat exchanger coil to ductwork 44 that directs the forced air to one or more areas to be serviced.

Such air handlers are generally cuboid in shape, having a “boxed top” above the air conditioning element. This boxed top results in the plenum 40 downstream of the air conditioning element. An air outlet in the top of the housing of the air handler 20 connects to the ductwork 44. Typically, this air outlet is about eight inches in diameter; significantly smaller than the flat top surface of the housing 24 of the air handler 20. As the air stream is forced through the smaller air outlet, turbulence is created. Further, some of the energy of the air stream is dissipated as it encounters the top of the housing 24 of the air handler 20, leading to additional energy spent to deliver the heated forced air. Still further, the turbulence and sudden distortion of the housing 24, which is typically made of sheet metal, when the fan in the air handler 20 commences operation due to the unnecessary pressure created within the plenum 40 create a significant amount of noise.

SUMMARY

In one aspect, there is provided an insert for an air handler, comprising a first end having a first opening therein for receiving conditioned air and a periphery being dimensioned to correspond substantially to the interior dimensions of a plenum of an air handler downstream of an air conditioning element, a second end having a second opening therein for permitting the conditioned air to exit the insert, and at least one wall extending between the first end and the second end defining a first air passage tapering from the first opening to the second opening.

The at least one wall can be four walls, and at least one of the walls can slope inwards from the first opening to the second opening. The insert can further comprise a cap extending between the four walls at the second end, the second opening being located in the cap.

The at least one wall can be four walls sloping inwards from the first opening to the second opening.

The at least one wall can be a continuous frustoconical wall.

The second opening can be dimensioned to match an air outlet in the air handler.

The second end can have a third opening therein for permitting the conditioned air to exit the insert, and the at least one wall can define the first air passage and a second air passage tapering from the first opening to the second opening.

In another aspect, there is provided an air handler, comprising a housing, an air conditioning element disposed in an air passage in the housing through which air is moved by a fan, a first air outlet in the housing, and at least one wall of the air passage within the housing tapering the air passage from between the air conditioning element and the first air outlet.

The at least one wall can be four walls, and at least one of the walls can slope inwards from the air conditioning element to the first air outlet.

The at least one wall can be four walls sloping inwards from the air conditioning element to the first air outlet.

The at least one wall can be a continuous frustoconical wall.

The air conditioning element can be a heat exchanger coil.

In a further aspect, there is provided an air handler, comprising a housing, an air conditioning element disposed in an air passage in the housing through which air is moved by a fan, a first air outlet in the housing, a second air outlet in the housing, and at least one wall of the air passage within the housing tapering the air passage from between the air conditioning element and the first and second air outlets.

These and other aspects are contemplated and described herein. It will be appreciated that the foregoing summary sets out representative aspects of an air handler and an insert for the same to assist skilled readers in understanding the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

A greater understanding of the embodiments will be had with reference to the Figures, in which:

FIG. 1 is a perspective view of an air handler;

FIG. 2 is a perspective view of an insert for an air handler such as that shown in FIG. 1 in accordance with an embodiment;

FIG. 3 is a sectional view of the air handler of FIG. 1 being fitted with the insert of FIG. 2;

FIG. 4 is a perspective view of another insert for an air handler such as that shown in FIG. 1 in accordance with another embodiment; and

FIG. 5 is a perspective view of an air handler in accordance with a further embodiment.

DETAILED DESCRIPTION

For simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the Figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the embodiments described herein. Also, the description is not to be considered as limiting the scope of the embodiments described herein.

Various terms used throughout the present description may be read and understood as follows, unless the context indicates otherwise: “or” as used throughout is inclusive, as though written “and/or”; singular articles and pronouns as used throughout include their plural forms, and vice versa; similarly, gendered pronouns include their counterpart pronouns so that pronouns should not be understood as limiting anything described herein to use, implementation, performance, etc. by a single gender; “exemplary” should be understood as “illustrative” or “exemplifying” and not necessarily as “preferred” over other embodiments. Further definitions for terms may be set out herein; these may apply to prior and subsequent instances of those terms, as will be understood from a reading of the present description.

In one embodiment, the following provides an insert for an air handler. The described insert comprises a first end, a second end, and at least one wall. The first end has a first opening therein for receiving conditioned air and a periphery being dimensioned to correspond substantially to the interior dimensions of a plenum of an air handler downstream of an air conditioning element. The second end has a second opening therein for permitting the conditioned air to exit the insert. The at least one wall extends between the first end and the second end defining an air passage tapering from the first opening to the second opening.

In another embodiment, an air handler is provided. The air handler has a housing, an air conditioning element, and an air outlet. The air conditioning element is disposed in an air passage in the housing through which air is moved by a fan. At least one wall of the air passage within the housing tapers the air passage between the air conditioning element and the first air outlet.

By tapering the air passage to the air outlet within the air handler via an insert, turbulence and noise can be decreased and the energy efficiency of the air handler can be increased in some scenarios.

FIG. 2 shows an insert 100 for an air handler in accordance with an embodiment. The insert 100 has four side walls 104 that are sloped inwardly upwardly, making the insert 100 frusto-pyramidal in shape. The bottom edges of the four side walls 104 define a periphery 108 of a first end 110 of the insert 100. The periphery 108 is dimensioned to correspond substantially to the interior dimensions of the plenum of an air handler downstream of an air conditioning element. The first end 110 is open. A second end 111 of the insert 100 has a cap 112 that spans between the four side walls 104. The cap 112 has an opening 116 dimensioned to correspond substantially to the dimensions of an air outlet in an air handler. The side walls 104 define an air passage through the insert 100 that is tapered from the opening defined by the periphery 108 towards the opening 116 in the cap 112. Four screw holes 120 are spaced apart in the cap 112.

The insert 100 can be made of any one of a number of suitable materials that can withstand the temperatures and humidity levels in the air passage of an air handler, such as corrosion-resistant sheet metal, rotationally-molded plastic, and vacuum-formed plastic. The inside or outside surface can be insulated via an insulator such as a half inch to a one inch layer of fiberglass or the like. Where insulation is employed on the inside surface of an insert, a smooth surface is preferably provided.

The side walls 104 and cap 112 of the insert 100 may be secured to each other via any one of a number of manners, such as soldering, welding, fastening via nuts and bolts or other suitable fasteners, a heat-resistant adhesive tape, etc. Two or more side walls 104 and/or the cap 112 may also be made from a single sheet of material and folded to the desired shape. It may be desirable to provide a continuous, air-tight joint between the side walls 104 and the cap 112 to ensure that, when the insert is positioned along the air passage inside an air handler, the air forced through the insert does not leak between the side walls 104 and the cap 112.

FIG. 3 shows the insert 100 installed in the air handler 20 of FIG. 1. In order to install the insert 100 in the air handler 20, a front panel of the air handler 20 may be removed by removing the screws holding it in place. Once the front panel is removed, the insert 100 may be inserted into the plenum 40 and slid fully in. In addition, the insert 100 may be moved upwards to place the cap 112 of the insert 100 in contact with the top wall of the housing 24 such that the opening 116 in the cap 112 is adjacent and aligned with the air outlet of the air handler 20. The insert 100 may then be secured in place to the housing 24 via fasteners and duct tape. Bolts may be inserted through the screw holes 120 of the cap 112 and corresponding holes in the top of the housing 24 of the air handler 20 and secured with nuts. Strips of duct tape may be used to secure the opening 116 in the cap 112 to the air outlet of the air handler 20. In addition, strips of duct tape may be used to secure the periphery 108 of the insert 100 against the interior of the housing 24 of the air handler 20.

As shown, the return port 28 of the air handler 20 enables air to enter the air handler 20. A blower fan 48 is positioned to draw the entering air and force it upwards through a heat exchanger coil 52. The blower fan 48 can be replaced by any suitable motor-driven fan for use in an air handler.

When installed, the insert 100 defines the air passage in the plenum 40 of the air handler 20 downstream of the heat exchanger coil 52. The side walls 104 taper the air passage from the heat exchanger coil 52 to the air outlet and the ductwork 44.

An alternative insert 200 in accordance with another embodiment is shown in FIG. 4. The insert 200 has a continuous frustoconical side wall 204. A periphery 208 of the continuous frustoconical side wall 204 at a first end 210 of the insert 200 has arcuate edges corresponding to the line along which the frustoconical side wall 204 intersects the profile of the interior of a housing of an air handler into which the insert 200 is to be installed. The first end 210 is open. An opening 212 is defined by the continuous frustoconical side wall 204 at a second end 216 of the insert 200. The opening 212 is dimensioned to correspond to an air outlet of an air handler into which the insert is to be installed.

The insert 200 can be made of any one of a number of suitable materials that can withstand the temperatures in the air passage of an air handler, such as corrosion-resistant sheet metal, rotationally-molded plastic, and vacuum-formed plastic. The inside surface can be insulated via an insulator such as a half inch to a one inch layer of fiberglass or the like. Where insulation is employed on the inside surface of an insert, a smooth surface is preferably provided.

The continuous frustoconical side wall 204 of the insert 200 may be constructed from one or more panels that are secured together. For example, the one or more panels may be soldered, welded, fastened via nuts and bolts or other suitable fasteners, taped with a heat-resistant adhesive tape, etc.

While the shape of the insert is described with reference to certain embodiments described herein, other shapes of the insert will occur to those skilled in the art. For example, an insert can be generally cuboid but may have one or more interior surfaces that provide tapering to an air passage defined between first and second ends of the insert. The interior walls defining the air passage can be planar, concave, convex, etc. Where the air handler is of another form, the air handler may be shaped to correspond to the interior of the air handler. For example, where the plenum of the air handler between the air conditioning element and the ductwork is cylindrical, the insert may be frustoconical.

Exterior walls or features can be provided for the insert. For example additional walls or features can be provided by the insert to stabilize the insert within the interior of a plenum of an air handler.

The insert can be sold assembled or unassembled. For example, where the side walls and/or cap are secured to one another via fasteners, the side walls and/or cap can be sold unassembled together with the fasteners.

The insert can also be made integral with the air handler prior to sale.

An air handler 300 in accordance with a further embodiment is shown in FIG. 5. In this embodiment, the air handler 300 is similar to the air handler 20 of FIG. 1, but is provided an internal air passage that is tapered between the air conditioning element and the air outlet. The air handler 300 has a housing 302 that has a return port 304 at a lower end thereof. The return port 304 permits the ingress of return air from an environment being conditioned. The return port 304 can be coupled to ducting through which return air is drawn. A blower fan positioned in a lower portion 308 inside the housing 302 draws ambient air via the return port 304 and forces an air stream upwards through a heat exchanger coil. The heat exchanger coil has an inlet port 312 and an outlet port 314 that are coupled via conduits to a water heater, such as an instantaneous water heater. A pump circulates water from the water heater through the heat exchanger coil via the conduits. As the air stream passes through the heat exchanger coil, the air is heated before it is forced upwards through a plenum 316 to ductwork 320 that directs the forced air to one or more areas to be serviced. The housing 302 at the plenum 316 is dimensioned to define a tapered air passage through the plenum 316.

Air handlers of other forms, such as cylindrical, may also be provided with tapered air passages through their plenum between the air conditioning element and the ductwork. For example, where the air handler is cylindrical, the plenum of the air handler may be frustoconical.

The air handler or insert may provide a tapered air passage to two or more air outlets connected to separate ductwork.

The air handler or insert can provide more than one tapered air passage. For example, for a multi-zone air handler where separate ductwork for each zone is directly connected to the air handler, the air handler or insert can provide a separate tapered air passage for each zone's ductwork.

While certain embodiments were described with respect to heat exchanger coils, it will be appreciated that the above approach can be used with air handlers with other types of air conditioning elements, such as humidifiers and dehumidifiers.

While, in the above-described embodiment, the air handler is provided with a single fan for generating an air stream through the air handler, it will be appreciated that the air handler can be alternatively configured with two or more separate fans.

One or more return ports can be provided to enable return air to enter the air handler. The return ports can be dedicated to serving a particular blower or can be used to enable a pool of air to enter the air handler for drawing by the blowers.

Although the invention has been described with reference to certain specific embodiments, various transformations thereof will be apparent to those skilled in the art. The scope of the claims should not be limited by the preferred embodiments, but should be given the broadest interpretation consistent with the description as a whole. 

1. An insert for an air handler, comprising: a first end having a first opening therein for receiving conditioned air and a periphery being dimensioned to correspond substantially to the interior dimensions of a plenum of an air handler downstream of an air conditioning element; a second end having a second opening therein for permitting the conditioned air to exit the insert; and at least one wall extending between the first end and the second end defining a first air passage tapering from the first opening to the second opening.
 2. The insert of claim 1, wherein the at least one wall comprises four walls, at least one of the walls sloping inwards from the first opening to the second opening.
 3. The insert of claim 2, further comprising a cap extending between the four walls at the second end, the second opening being located in the cap.
 4. The insert of claim 1, wherein the at least one wall comprises four walls sloping inwards from the first opening to the second opening.
 5. The insert of claim 1, wherein the at least one wall comprises a continuous frustoconical wall.
 6. The insert of claim 1, wherein the second opening is dimensioned to match an air outlet in the air handler.
 7. The insert of claim 1, wherein the second end has a third opening therein for permitting the conditioned air to exit the insert, and the at least one wall defines the first air passage and a second air passage tapering from the first opening to the second opening.
 8. An air handler, comprising: a housing; an air conditioning element disposed in an air passage in the housing through which air is moved by a fan; a first air outlet in the housing; and at least one wall of the air passage within the housing tapering the air passage from between the air conditioning element and the first air outlet.
 9. The air handler of claim 8, wherein the at least one wall comprises four walls, at least one of the walls sloping inwards from the air conditioning element to the first air outlet.
 10. The air handler of claim 8, wherein the at least one wall comprises four walls sloping inwards from the air conditioning element to the first air outlet.
 11. The air handler of claim 8, wherein the at least one wall comprises a continuous frustoconical wall.
 12. The air handler of claim 8, wherein the air conditioning element is a heat exchanger coil.
 13. An air handler, comprising: a housing; an air conditioning element disposed in an air passage in the housing through which air is moved by a fan; a first air outlet in the housing; a second air outlet in the housing; and at least one wall of the air passage within the housing tapering the air passage from between the air conditioning element and the first and second air outlets. 